Method for weaving contoured thread connected dual wall inflatable fabric



Dec. 21, 1965 GROVER 3,224,466

METHOD FOR WEAVING CONTOURED THREAD CONNECTED v DUAL WALL INFLATABLE FABRIC Filed Jan. 51, 1964 3 Sheets-Sheet 1 43 INVENTOR. 4 ELL/07' B 'GROVER ATTORNEY Dec. 21, 1965 E. B. GROVER 3,224,466

METHOD FOR WEAVING CONTOURED THREAD CONNECTED DUAL WALL INFLATABLE FABRIC Filed Jan 51, 1964 3 Sheets-Sheet 2 FEED BAR INVENTOR ELL/07' B. GROVE/ ATTORNEY Dec. 21, 1965 GRQVER 3,224,466

METHOD FOR WEAVING CONTOURED THREAD CONNECTED DUAL WALL INFLATABLE FABRIC Filed Jan. 51. 1964 3 Sheets-Sheet 3 INVENTOR. ELL/OT B. GROVER v If I ATTORNEY United States Patent Oflice 3,224,466 Patented Dec. 21, 1965 Delaware Filed Jan. 31, 1964, Ser. No. 341,719 3 Claims. (Cl. 13920) This invention relates to a method for weaving contoured thread connected dual wall inflatable fabric, and more particularly to a method for weaving two fabrics in a spaced relationship with extended drop yarns con-- necting therebetween so that when the fabrics are moved apart after weaving, a desired contour therebetween is attained by the extended lengths of the drop yarns.

Thread-connected dual wall inflatable fabric is manufactured and sold by Goodyear Aerospace Corporation of Akron, Ohio, under the trademark Airmat registered in the US. Patent Oflice.

Thread-connected dual wall inflatable fabric, hereinafter for simplicity called inflatable fabric, has been made with the connecting threads, sometimes called drop yarns, of fine steel wire or of light but strong natural or synthetic fibers or filaments. Inflatable fabric of this type when inflated provides a high strength per unit weight ratio. It consists of an upper and lower woven fabric connected by drop yarns of equal length for fiat inflatable fabric or varying lengths for contoured inflatable fabric. At present, however, it is not possible to accurately and/ or automatically vary the length of the drop yarns to make two dimensional or complex contoured inflatable fabrics. Thus, using the plush or carpet looms of the art only flat inflatable fabric of approximately three inches thickness is possible; however, inflatable fabric can be made up to approximately six inches in thickness by including false picks to extend the drop yarns which picks are later removed.

Until the technique of weaving complex contoured inflatable fabric, as disclosed hereinafter, was developed, it was necessary to cut fabrics into strips and gores which were sewn together to produce complex shapes, such as airplane tails and wings. This procedure was not only costly and time consuming, but also precluded, to any great extent, any attempt to produce such shapes with any satisfactory degree of uniformity.

Therefore, it is the general object of the invention to avoid and overcome the foregoing and other difliculties of prior art practices by the provisions of a method to weave contoured inflatable fabric on a double fabric plush loom by extending the drop yarns to the desired length between the fabrics during the weaving.

A further object of the invention is to provide a method of weaving contoured inflatable fabric on a double fabric plush type loom which produces fabric with contours which are highly accurate and controllable to provide a precision inflatable fabric with a high strength to weight ratio.

- A further object of the invention is to provide a method to weave contoured inflatable fabric whereby any desired contour can be imparted between the fabric layers by variably extending the drop yarns between the fabrics and weaving the extended drop yarns securely into place to maintain the desired extension thereof.

Another object of the invention is to provide a method of weaving contoured inflatable fabric which is simple, highly accurate, extremely effective, and which is very low in cost compared to previous methods.

The aforesaid objects of the invention and other objects which will become apparent as the description proceeds are achieved by providing a method to make deep piled contour inflatable fabric on a double fabric plush loom which includes the steps of weaving in substantially parallel spaced relationship a top and bottom fabric each of longitudinally extending warp yarn and transversely extending weft yarn, maintaining the woven fabrics in substantially the same spaced parallel relationship while moving them away from the weaving edge, weaving a plurality of drop yarns longitudinally into each fabric, crossing the drop yarns over from one fabric to the other and simultaneously extending the length of the drop yarns variably depending upon the desired contour between the fabrics, and weaving the crossed over and extended drop yarn longitudinally into their respective fabrics to hold them in position.

For a better understanding of the invention reference should be had to the accompanying drawings, wherein:

FIGURE 1 is a schematic illustration of weaving double fabric on a plush type loom with means provided to extend the crossed-over drop yarns;

FIGURE 2 is a perspective view of a drop yarn extension bar mechanism adapted to provide the drop yarn extension method of the invention;

' to provide transversely tapered deep pile inflatable fabric;

FIGURE 5 is an illustration of drop yarn extension to provide contoured inflatable fabric in the transverse direction;

FIGURE 6 is an illustration of drop yarn extension to provide tapered inflatable fabric in the longitudinal direction; and

FIGURE 7 is a perspective illustration of another embodiment of the invention to achieve drop yarn extension.

For a better understanding of the method of the invention reference should be had to the drawings where in FIGURE 1 the numeral 1 indicates a group of six top heddle frames adapted to control a plurality of upper Warp yarns 2 and 3. The numeral 4 represents generally a group of six heddle frames adapted to control a plurality of bottom warp yarns 5 and 6. A pair of heddle desired strength-weight ratio.

frames, indicated by the numeral 7, provide control for a plurality of drop yarns 8 and 9. The invention contemplates that all the yarns be metallic of between about .0015 and about .005 inch in diameter to provide the However, nylon, rayon, or other suitable man made or natural yarns could be utilized. I

The warp yarns 2 and 3 are separated by the heddle group 1 to provide the shed 10 wherein a weft yarn 11 may be passed by a suitable shuttle mechanism (not shown). Likewise, the warp yarns 5 and 6 are spread by the heddle group 4 to provide a shed 12 which receives a weft yarn 13 again passed by a suitable shuttle mechanism (not shown). In order to beat up the weft yarns. 11 and 13, a suitable reed assembly 14 may be provided. The warp yarns 2 and 3, and 5 and 6 are tensioned= outwardly on a pair of gage angle frames 15 and 16 to allow the weft yarns 11 and 13 to be beaten up against the flush ends 17 and 18, respectively, of frames 15 and 16 to thereby form a top fabric layer 19 and a bottom fabric layer 20.

The drop yarns 8 and 9 are woven into the top and bottom fabric layers longitudinally and substantially parallel to the Warp yarn. However, the drop yarns are crossed over from one fabric layer to the other between about every 2 to about 20 picks or passes of the weft yarns. Thus, in FIGURE 1, as illustrated, the drop yarns 8 and 9 have been crossed over by movement of the heddles 7 forming a cross over not a point 21. In

order to provide the desired drop yarn extension to achieve a desired contoured relationship between the top and the bottom fabric layers, an extension rod 22 is operatively positioned behind the cross over 21 between the drop yarns 8 and 9 and in front of the reed mechanism 14. The extension bar 22 is then moved horizontally forward between the gage angle frames 15 .and 16 to a point indicated by the dotted lines and identified by numeral 23. The length that the drop yarns 8 and 9 are extended by the extension bar 22 is dependent upon the desired cont-our between the fabric layers 19 and 20. Note that previous extensions of other drop yarns already woven into the fabric are shown and indicated by numerals 24 through 27. As will be more fully described hereinafter, the extension bar 22 may be of various shape or various angle extending across the width of the fabric layers to make the extension of the drop yarns variable to provide the desired contour. Also, the bar 22 may remain between the woven fabrics until completion of all weaving to prevent tangling of the drop yarns as will be more fully explained hereinafter, or the bar 22 may be removed after the drop yarns 8 and 9 have been woven back into the fabrics after the extension thereof.

' With reference to FIGURE 2 one possible method or apparatus to achieve the drop yarn extension method is illustrated wherein an extension bar 30 is adapted for sliding engagement with a pair of extension bar tracks 31 and 32, respectively, which are mounted horizontally between a top fabric 33 and a bottom fabric 34. A pair of drop yarns 35 and 36 are passed through a reed mechanism 37 and adapted to be extended by the extension bar 30 to a point 38, indicated by the dotted lines.

FIGURE 3 is an illustration of longitudinal drop yarn extension by an extension bar 40 uniformly across the width of fabric layers 41 and 42 to provide a deep pile inflatable fabric having an inflated thickness 43, compared to a loomed thickness 44, as indicated in the cross sectional View AA.

FIGURE 4 is an illustration of providing transversely tapered inflatable fabric wherein the drop yarns on one side are extended further than the drop yarns on the other side because the extension bar 40a is slanted at an angle, as illustrated. In this illustration the cross sectional view of the inflatable fabric in the direction A-A will provide an inflated thickness 43a as compared to a loom thicknsss 44a.

FIGURE illustrates the formation of contoured inflatable fabric when the extension bar 40b is curved providing greater extension of the drop yarns at the center thereof than on the ends. In this instance, as illustrated in the cross sectional view AA, the inflated thickness 43b provides the desired contour whereas the loomed thickness 44b is similar to the loom thickness in FIG- URES? and 4.

FIGURE 6 illustrates a method of tapering the inflatable fabric in the longitudinal direction wherein the extension bar 400 is moved increasingly less or increasingly more as the fabric layers are woven to provide a longitudinally'tapered inflatable fabric which when viewed in longitudinal section A.A has an inflated thickness 43c, and again the same loomed thickness 440 as in the examples illustrated in FIGURES 3 through 5.

FIGURE 7 illustrates a perspective view of another apparatus to perform the method of the invention. Specifically, a top fabric layer 50 and a bottom fabric layer 51, as provided by the basic loom are illustrated.

Drop yarns 52 and 53 pass through a reed mechanism 54 and thence are crossed over to the fabric layers 50 and 51. The invention contemplates that an easily deformable rod, preferably made of metallic material, be used as an extension bar 55. The bar 55 is properly contoured to the desired position by means of a plurality of elongated gages 56 and 57, respectively, adapted to removably receive the bar 55 through elongated slots 58 and 59, respectively. The drop yarns 52 and 53 are so crossed over that the extension bar 55 will be placed behind the 4 crossover point 60 and in front of the reed mechanism 54. Thus, when the gages 56 and 57 are moved forwardly between the fabric layers 50 and 51 to provide the desired extension to the drop yarns, the gages will insure the proper contour of the bar 55 to provide the proper extension of the drop yarns to a point indicated by the dotted lines 61. The invention contemplates that the gages 56 and 57 are only two of a plurality, with each individual gage being controlled by a separate mechanism according to the picks of the weft which properly positions the gage to determine the contour of the extension bar 55 to insure that each drop yarn will be extended the desired distance.

Thus, it is seen that the objects of the invention' have been achieved by providing a method to weave deep piled contoured inflatable fabric by variably extending the drop yarns between the top and bottom fabric layers during the weaving thereof to provide longitudinallv or transversely tapered or contoured deep pile inflatable fabric. It should be understood that the yarn mentioned heretofore may be wire, nylon, rayon or any other suitable material to provide the desired strength-weight ratio; Various embodiments of apparatus to achieve the drop yarn extension have been illustrated and described, but

it is to beunderstood that the method of drop yarn extension to'achieve deep pile contour inflatable fabric is the primary object of the invention, and that various other apparatus structures might be utilized to achieve the drop yarn extension equally as well as those presented herein. It is to be further understood that the drop yarn extension is made by crossing longitudinally extending drop yarns from the top fabric to the bottom fabric or vice versa with the yarns being extended a desired length before being rewoven into their respective fabric layers. Thus, although the fabric layers are still woven in substantially parallel relationship to each other and at a uniform spacing throughout their length, the drop yarn extension provides desired contours or shapes to the fabrics when they may be made gas impervious and inflated, or moved apart in some other manner to provide the extension of the drop yarns.

While in accordance with the patent statutes one best known embodiment of the invention has been illustrated and described in detail, it is to be particularly understood that the invention is not limited thereto or thereby, but that the inventive scope is defined in the appended claims.

What is claimed is: e

1. A method for weaving deep pile contoured inflata' ble fabric which includes the steps of weaving two fabrics of warp and weft yarns in substantially parallel and spaced relationship, taking the fabrics away from the weaving edge in substantially straight and parallel spaced relationship,

weaving a plurality of drop yarns-longitudinally into the fabrics in substantially parallel relationship to the warp yarns, crossing said drop yarns over from one fabric to the other,

extending the crossed over drop yarns pre-determined distances to achieve a desired spaced relationship between the fabrics when the fabrics are moved apart after the weaving is completed, where such extension is independent of anyother weaving operation and where the extensions of individual drop yarns are variable across the width'of the fabrics,and

subsequently weaving the extended and crossed over drop yarns into their respective fabrics to hold the drop yarns in position before the next cross over thereof.

2. A method for weaving deep pile contoured inflatable fabric which includes the steps of weaving two fabrics of metallic yarns of between about .0015 and about .005 inch in diameter'in substantiallyparallel and spaced relationship, v weaving a plurality of drop yarns longitudinally into the fabrics in substantially parallel relationship to the warp yarns,

crossing said drop yarns over from one fabric to the other,

extending the crossed over drop yarns variable predetermined distances to achieve a desired contoured spaced relationship between the fabrics when the fabrics are moved apart after the weaving is completed, and

weaving the extended and crossed over drop yarns into their respective fabrics to hold the drop yarns in position before the next cross over thereof.

3. A method for weaving contoured inflatable fabric which includes the steps of weaving two fabrics in substantially parallel spaced relationship,

Weaving drop yarns longitudinally into the fabrics,

crossing the drop yarns over between fabrics at a plurality of intervals on the longitudinal length of the fabrics,

extending the drop yarns variable pro-determined distances after the cross over thereof,

retaining the drop yarns in their extended position to eliminate the tangling thereof, and

weaving the extended and crossed over drop yarns into their respective fabrics to secure them in position.

References Cited by the Examiner UNITED STATES PATENTS Marigold '139-384 Holmes 139-20 Schaar 139-384 Brindle 139-20 Garner 139-397 X MacIntyre 139-410 Ford 139-410 Morgan 139-21 Mauney et a1 139-410 X Neisler 139-20 X Foster et al 139-410 X Netherlands.

DONALD W. PARKER, Primary Examiner.

JAMES KEE CHI, Assistant Examiner. 

1. A METHOD FOR WEAVING DEEP PILE CONTOURED INFLATABLE FABRIC WHICH INCLUDES THE STEPS OF WEAVING TWO FABRICS OF WARP AND WEFT YARNS IN SUBSTANTIALLY PARALLEL AND SPACED RELATIONSHIP, TAKING THE FABRICS AWAY FROM THE WEAVING EDGE IN SUBSTANTIALLY STRAIGHT AND PARALLEL SPACED RELATIONSHIP, WEAVING A PLURALITY OF DROP YARNS LONGITUDINALLY INTO THE FABRICS IN SUBSTANTIALLY PARALLEL RELATIONSHIP TO THE WARP YARNS, CROSSING SAID DROP YARNS OVER FROM ONE FABRIC TO THE OTHER, EXTENDING THE CROSSED OVER DROP YARNS PRE-DETERMINED DISTANCES TO ACHIEVE A DESIRED SPACED RELATIONSHIP BETWEEN THE FABRICS WHEN THE FABRICS ARE MOVED APART AFTER THE WEAVING IS COMPLETED, WHERE SUCH EXTENSION IS INDEPENDENT OF ANY OTHER WEAVING OPERATION AND WHERE THE EXTENSIONS OF INDIVIDUAL DROP YARNS ARE VARIABLE ACROSS THE WIDTH OF THE FABRICS, AND SUBSEQUENTLY WEAVING THE EXTENDED AND CROSSED OVER DROP YARNS INTO THEIR RESPECTIVE FABRICS TO HOLD THE DROP YARNS IN POSITION BEFORE THE NEXT CROSS OVER THEREOF. 